1. Tech 149: Unit 1 
Introduction to CIM Technology

2. Introduction
Manufacturing is a collection of interrelated activities that includes product design and documentation, material selection, planning, production, quality assurance, management, and marketing of goods
The fundamental goal of manufacturing is to use these activities to convert raw materials into finished goods on a profitable basis

3. Introduction
The lessons learned in the 1970s and 1980s resulted in changes across U.S. industries
As a result of improved manufacturing practices, U.S. industries reclaimed a leadership role by the mid-1990s and will continue that leadership role in the next millennium

4. Three Stages of Manufacturing Retreat:
Emergence of small electronic consumer goods during the Vietnam War
2. Japanese practice of copying successful U.S. products
3. Offshore companies and rapid product development in the late 1980s

5. External Challenges Result from:
Niche market entrants, traditional competition, suppliers, partnerships and alliances, customers, global economy, cost of money, and the Internet

6. Internal Challenges Result in:
A plan, process, or manufacturing strategy that forces congruence between the corporate objectives and marketing goals and production capability of a company

7. Order-winning Criteria are:
Price
Quality
Delivery speed
Innovation ability

8. Product Life Cycle Curve
Sales
Introduction Growth Maturity Decline/Commodity

9. Changing the Product Life Cycle:
Kaizen or improvement of current model
Leaping or developing a new product similar to the initial product
Innovation or using genuine new product invention to identify follow-up merchandise

10. Order-winning Versus Order-Qualifying Criteria:
Market share is increased when the order-winning criteria are understood and executed better than the competition

11. Meeting the Internal Challenges:
Analyze every product and agree on the order-qualifying and order-winning criteria for the product at the current stage in it’s life
Project the order-winning criteria for the future stages in every product’s life
Determine the fit between the required process capability and the existing capability in manufacturing
Change/modify the marketing goals, or upgrade the manufacturing processes and infrastructure to force internal consistency

12. World-class Order-winning Criteria:
Setup time or time required to get a machine ready for production
Quality or % of defective parts produced or % of total sales
Manufacturing space ratio or a measure of how efficiently manufacturing space is utilized
Inventory: Velocity/residence time

13. World-class Order-winning Criteria:
Flexibility or a measure of the number of different parts that can be produced on the same machine
Distance or total linear feet of a part’s travel through the plant from raw material in receiving to finished products in shipping
Uptime or % of time a machine is producing to specifications compared to total time that production can be scheduled

14. Computer-Integrated- Manufacturing
The Solution IS:
Computer-Integrated- Manufacturing
(CIM)

15. CIM has Different Definitions for Different Users
i. Shop communications
ii. Recurring processes
iii. Non-recurring processes
iv. Engineering/manufacturing communication
v. Other users
vi. Improving communication through CIM

16. Computer Integrated Manufacturing
Refers to the technology, tool or method used to improve entirely the design and manufacturing process and increase productivity, to help people and machines to communicate. It includes CAD (Computer-Aided Design), CAM (Computer- Aided Manufacturing), CAPP (Computer-Aided Process Planning, CNC (Computer Numerical Control Machine tools), DNC (Direct Numerical Control Machine tools), FMS (Flexible Machining Systems), ASRS (Automated Storage and Retrieval Systems), AGV (Automated Guided Vehicles), use of robotics and automated conveyance, computerized scheduling and production control, and a business system integrated by a common database. (Houston Cole Library)

17. Computer Integrated Manufacturing
Is the process of automating various functions in a manufacturing company (business, engineering, and production) by integrating the work through computer networks and common databases. CIM is a critical element in the competitive strategy of global manufacturing firms because it lowers costs, improves delivery times and improves quality. (Amatrol)

18. Computer-integrated Manufacturing Defined:
CIM is the integration of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personal efficiency

19. SME New Manufacturing Enterprise Wheel

20. What is CIM? C + I + M C = Computer i. Enabling tool
ii. Information flow
iii. Information management

21. What is CIM? I = Integrated i. Integration vs. interfacing
ii. Shared information
iii. Shared functionality
M = Manufacturing
i. Production control
ii. Production scheduling
iii. Process design
iv. Product design
v. Manufacturing enterprise

22. CIM Components or Subsystems Include:
CAD
CAM
CAPP
CAE
ERP
PLC
Computers
Automated conveyors
CNC
DNC
Robotics
Controllers
FMS
ASRS
AGV
Monitoring equipment
Others

23. Sample CIM Sub-Systems
Design
Man
Prod Eng
Sales & Mark

24. CIM DATABASE INS CAD ROB CUS MAR MRP AGV CAE EST CNC DOC PUR CAM ANA
BOM
EST
CAM
CAPP
PUR
CAD
DOC
MRP
Components of Computer-Integrated Manufacturing

25. The Centrality of Manufacturing in a Market-Oriented Economy
Production System triad
Mkt
Des
Pro Eng
Man

26. Production Strategy Classification:
Relative to customer lead time
Relative to manufacturing lead time
Manufacturing lead time and customer lead time must be matched

27. Production Strategies Used to Match Customer and Manufacturing Lead Times:
Engineer to order (ETO)
Make to order (MTO)
Assemble to order (ATO)
Make to stock (MTS)

28. Groover Chapter 1: Introduction Production System Defined
A collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company
Two categories:
Facilities – the factory and equipment in the facility and the way the facility is organized (plant layout)
Manufacturing support systems – the procedures used by a company to manage production and to solve technical and logistics problems in ordering materials, moving work through the factory, and ensuring that products meet quality standards

29. The Production System

30. Production System Facilities
Facilities include the factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations
Plant layout – the way the equipment is physically arranged in the factory
Manufacturing systems – logical groupings of equipment and workers in the factory
Production line
Stand-alone workstation and worker

31. Manufacturing Systems
Three categories in terms of the human participation in the processes performed by the manufacturing system:
Manual work system - a worker performing one or more tasks without the aid of powered tools, but sometimes using hand tools
Worker-machine system - a worker operating powered equipment
Automated system - a process performed by a machine without direct participation of a human

32. Manufacturing Support Systems
Manufacturing support involves a sequence of activities that consists of four functions:
Business functions - sales and marketing, order entry, cost accounting, customer billing
Product design - research and development, design engineering, prototype shop
Manufacturing planning - process planning, production planning, MRP, capacity planning
Manufacturing control - shop floor control, inventory control, quality control

33. Sequence of Information-Processing Activities in a Manufacturing Firm

34. Automation in Production Systems
Two categories of automation in the production system:
Automation of manufacturing systems in the factory
Computerization of the manufacturing support systems
The two categories overlap because manufacturing support systems are connected to the factory manufacturing systems
Computer-Integrated Manufacturing (CIM)

35. Computer Integrated Manufacturing

36. Automated Manufacturing Systems
Examples:
Automated machine tools
Transfer lines
Automated assembly systems
Industrial robots that perform processing or assembly operations
Automated material handling and storage systems to integrate manufacturing operations
Automatic inspection systems for quality control

37. Automated Manufacturing Systems
Three basic types:
Fixed automation
Programmable automation
Flexible automation

38. Fixed Automation
A manufacturing system in which the sequence of processing (or assembly) operations is fixed by the equipment configuration
Typical features:
Suited to high production quantities
High initial investment for custom-engineered equipment
High production rates
Relatively inflexible in accommodating product variety

39. Programmable Automation
A manufacturing system designed with the capability to change the sequence of operations to accommodate different product configurations
Typical features:
High investment in general purpose equipment
Lower production rates than fixed automation
Flexibility to deal with variations and changes in product configuration
Most suitable for batch production
Physical setup and part program must be changed between jobs (batches)

40. Flexible Automation
An extension of programmable automation in which the system is capable of changing over from one job to the next with no lost time between jobs
Typical features:
High investment for custom-engineered system
Continuous production of variable mixes of products
Medium production rates
Flexibility to deal with soft product variety

41. Product Variety and Production Quantity for Three Automation Types

42. Computerized Manufacturing Support Systems
Objectives of automating the manufacturing support systems:
To reduce the manual and clerical effort in product design, manufacturing planning and control, and the business functions
Integrates computer-aided design (CAD) and computer-aided manufacturing (CAM) in CAD/CAM
CIM includes CAD/CAM and the business functions of the firm

43. Reasons for Automating
Increase labor productivity
Reduce labor cost
Mitigate the effects of labor shortages
Reduce or remove routine manual and clerical tasks
Improve worker safety
Improve product quality
Reduce manufacturing lead time
Accomplish what cannot be done manually
Avoid the high cost of not automating

44. Manual Labor in Production Systems
Is there a place for manual labor in the modern production system?
Answer: YES
Two aspects:
Manual labor in factory operations
Labor in manufacturing support systems

45. Manual Labor in Factory Operations
The long term trend is toward greater use of automated systems to substitute for manual labor
When is manual labor justified?
Some countries have very low labor rates and automation cannot be justified
Task is technologically too difficult to automate
Short product life cycle
Customized product requires human flexibility
To cope with ups and downs in demand
To reduce risk of new product failure

46. Labor in Manufacturing Support Systems
Product designers who bring creativity to the design task
Manufacturing engineers who
Design the production equipment and tooling
And plan the production methods and routings
Equipment maintenance
Programming and computer operation
Engineering project work
Plant management

47. Automation Principles and Strategies
The USA Principle
Ten Strategies for Automation and Process Improvement
Automation Migration Strategy

48. U.S.A Principle Understand the existing process Simplify the process
Input/output analysis
Value chain analysis
Charting techniques and mathematical modeling
Simplify the process
Reduce unnecessary steps and moves
Automate the process
Ten strategies for automation and production systems
Automation migration strategy

49. Ten Strategies for Automation and Process Improvement
Specialization of operations
Combined operations
Simultaneous operations
Integration of operations
Increased flexibility
Improved material handling and storage
On-line inspection
Process control and optimization
Plant operations control
Computer-integrated manufacturing

50. Automation Migration Strategy For Introduction of New Products
Phase 1 – Manual production
Single-station manned cells working independently
Advantages: quick to set up, low-cost tooling
Phase 2 – Automated production
Single-station automated cells operating independently
As demand grows and automation can be justified
Phase 3 – Automated integrated production
Multi-station system with serial operations and automated transfer of work units between stations

51. Technological Categories of the Production System

52. Chapter 2: Manufacturing Operations
Sections:
Manufacturing Industries and Products
Manufacturing Operations
Production Facilities
Product/Production Relationships

53. Manufacturing: Technological Definition
Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products
Manufacturing also includes the joining of multiple parts to make assembled products
Accomplished by a combination of machinery, tools, power, and manual labor.
Almost always carried out as a sequence of operations

54. Manufacturing: Technological Definition

55. Manufacturing: Economic Definition
Transformation of materials into items of greater value by means of one or more processing and/or assembly operations
Manufacturing adds value to the material
Examples:
Converting iron ore to steel adds value
Transforming sand into glass adds value
Refining petroleum into plastic adds value

56. Manufacturing: Economic Definition

57. Classification of Industries
Primary industries – cultivate and exploit natural resources
Examples: agriculture, mining
Secondary industries – convert output of primary industries into products
Examples: manufacturing, power generation, construction
Tertiary industries – service sector
Examples: banking, education, government, legal services, retail trade, transportation

58. Manufacturing Operations
There are certain basic activities that must be carried out in a factory to convert raw materials into finished products
For discrete products:
Processing and assembly operations
Material handling
Inspection and testing
Coordination and control

59. Classification of manufacturing processes

60. Processing Operations
Shaping operations
Solidification processes
Particulate processing
Deformation processes
Material removal processes
Additive manufacturing (a.k.a. rapid prototyping)
Property-enhancing operations (heat treatments)
Surface processing operations
Cleaning and surface treatments
Coating and thin-film deposition

61. Assembly Operations Joining processes Mechanical assembly Welding
Brazing and soldering
Adhesive bonding
Mechanical assembly
Threaded fasteners (e.g., bolts and nuts, screws)
Rivets
Interference fits (e.g., press fitting, shrink fits)
Other

62. Other Factory Operations
Material handling and storage
Inspection and testing
Coordination and control

63. Material Handling and Storage
Material transport
Vehicles, e.g., forklift trucks, AGVs, monorails
Conveyors
Hoists and cranes
Storage systems
Automatic identification and data capture (AIDC)
Bar codes
RFID
Other AIDC

64. Time Spent by a Part in a Typical Metal Machining Batch Factory

65. Inspection and Testing
Inspection – examination of the product and its components to determine whether they conform to design specifications
Inspection for variables – measuring
Inspection for attributes – gaging
Testing – observing the product (or part, material, subassembly) during actual operation or under conditions that might occur during operation

66. Coordination and Control
Regulation of the individual processing and assembly operations
Process control
Quality control
Management of plant level activities
Production planning and control

67. Production Facilities
A manufacturing company attempts to organize its facilities in the most efficient way to serve the particular mission of the plant
Certain types of plants are recognized as the most appropriate way to organize for a given type of manufacturing
The most appropriate type depends on:
Types of products made
Production quantity
Product variety

68. Production Quantity
Number of units of a given part or product produced annually by the plant
Three quantity ranges:
Low production – 1 to 100 units
Medium production – 100 to 10,000 units
High production – 10,000 to millions of units

69. Product Variety
Refers to the number of different product or part designs or types produced in the plant
Inverse relationship between production quantity and product variety in factory operations
Product variety is more complicated than a number
Hard product variety – products differ greatly
Few common components in an assembly
Soft product variety – small differences between products
Many common components in an assembly

70. Low Production Quantity
Job shop – makes low quantities of specialized and customized products
Includes production of components for these products
Products are typically complex (e.g., specialized machinery, prototypes, space capsules)
Equipment is general purpose
Plant layouts:
Fixed position
Process layout

71. Medium Production Quantities
Batch production – A batch of a given product is produced, and then the facility is changed over to produce another product
Changeover takes time – setup time
Typical layout – process layout
Hard product variety
Cellular manufacturing – A mixture of products is made without significant changeover time between products
Typical layout – cellular layout
Soft product variety

72. High Production
Quantity production – Equipment is dedicated to the manufacture of one product
Standard machines tooled for high production (e.g., stamping presses, molding machines)
Typical layout – process layout
Flow line production – Multiple workstations arranged in sequence
Product requires multiple processing or assembly steps
Product layout is most common

73. Chapter 3: Manufacturing Metrics and Economics
Sections:
Production Performance Metrics
Manufacturing Costs

74. Production Performance Metrics
Cycle time Tc
Production rate Rp
Availability A
Production capacity PC
Utilization U
Manufacturing lead time MLT
Work-in-progress WIP

75. Operation Cycle Time Typical cycle time for a production operation:
Tc = To + Th + Tth
where
Tc = cycle time
To = processing time for the operation
Th = handling time (e.g., loading and unloading the production machine), and
Tth = tool handling time (e.g., time to change tools)

76. Production Rate Batch production: batch time Tb = Tsu + QTc
Average production time per work unit Tp = Tb/Q
Production rate Rp = 1/Tp
Job shop production:
For Q = 1, Tp = Tsu + Tc
For quantity high production:
Rp = Rc = 60/Tp since Tsu/Q  0
For flow line production
Tc = Tr + Max To and Rc = 60/Tc

77. Availability Availability = proportion uptime of the equipment
where MTBF = mean time between failures, and MTTR = mean time to repair

78. Availability
Key: MTBF = mean time between failures, MTTR = mean time to repair.

79. Production Capacity
Defined as the maximum rate of output that a production facility (or production line, or group of machines) is able to produce under a given set of operating conditions
When referring to a plant or factory, the term plant capacity is used
Assumed operating conditions refer to:
Number of shifts per day
Number of hours per shift
Employment levels

80. Plant Capacity
Simplest case is quantity production in which there are:
n production machines in the plant and they all produce the same part or product
Each machine produces at the same rate Rp
PC = n Hpc Rp
where PC = plant capacity for a defined period (e.g. a week),
Hpc = number of hours in the period being used to measure plant capacity, hr/period

81. How to Adjust Plant Capacity
Over the short term:
Increase or decrease number workers w
Increase or decrease shifts per week
Increase or decrease hours per shift (e.g., overtime)
Over the intermediate and long terms:
Increase number of machines n
Increase production rate Rp by methods improvements and/or processing technology

82. Utilization
Defined as the proportion of time that a productive resource (e.g., a production machine) is used relative to the time available under the definition of plant capacity

83. Manufacturing Lead Time
Defined as the total time required to process a given part or product through the plant, including any time for delays, material handling, queues before machines, etc.
MLT = no (Tsu + QTc + Tno) where
MLT = manufacturing lead time
no = number of operations
Tsu = setup time
Q = batch quantity
Tc cycle time per part, and
Tno = non-operation time

84. Work-In-Process
Defined as the quantity of parts or products currently located in the factory that either are being processed or are between processing operations
WIP = Rpph (MLT)
where
WIP = work-in-process, pc
Rpph = hourly plant production rate, pc/hr;
MLT = manufacturing lead time, hr

85. Manufacturing Costs Two major categories of manufacturing costs:
Fixed costs - remain constant for any output level
Variable costs - vary in proportion to production output level
Adding fixed and variable costs
TC = FC + VC(Q)
where
TC = total costs
FC = fixed costs (e.g., building, equipment, taxes)
VC = variable costs (e.g., labor, materials, utilities)
Q = output level.

86. Manufacturing Costs Alternative classification of manufacturing costs:
Direct labor - wages and benefits paid to workers
Materials - costs of raw materials
Overhead - all of the other expenses associated with running the manufacturing firm
Factory overhead
Corporate overhead

87. Typical Manufacturing Costs (J Black)

88. Cost of Equipment Usage
Hourly cost of worker-machine system:
Co = CL(1 + FOHRL) + Cm(1 + FOHRm)
where
Co = hourly rate, $/hr;
CL = labor rate, $/hr;
FOHRL = labor factory overhead rate,
Cm = machine rate, $/hr;
FOHRm = machine factory overhead rate

89. Cost of a Manufactured Part
Defined as the sum of the production cost, material cost, and tooling cost Cost for each unit operation = CoiTpi + Cti, where Coi = cost rate to perform unit operation i, Tpi = production time for operation i, Cti = tooling cost for operation i Total unit cost is the sum of the unit costs plus material cost Cpc = Cm + (CoiTpi + Cti), where Cpc = cost per piece, Cm = cost of starting material

90. Chapter 4: Introduction to Automation
Sections:
Basic Elements of an Automated System
Advanced Automation Functions
Levels of Automation

91. Automation Defined
Automation is the technology by which a process or procedure is accomplished without human assistance
Basic elements of an automated system:
Power - to accomplish the process and operate the automated system
Program of instructions – to direct the process
Control system – to actuate the instructions

92. Power to Accomplish the Automated Process
Power for the process
To drive the process itself
To load and unload the work unit
Transport between operations
Power for automation
Controller unit
Power to actuate the control signals
Data acquisition and information processing

93. Program of Instructions
Set of commands that specify the sequence of steps in the work cycle and the details of each step
Example: NC part program
During each step, there are one or more activities involving changes in one or more process parameters
Examples:
Temperature setting of a furnace
Axis position in a positioning system
Motor on or off

94. Decision-Making in a Programmed Work Cycle
Following are examples of automated work cycles in which decision making is required:
Operator interaction
Automated teller machine
Different part or product styles processed by the system
Robot welding cycle for two-door vs. four door car models
Variations in the starting work units
Additional machining pass for oversized sand casting

95. Control System – Two Types
Closed-loop (feedback) control system – a system in which the output variable is compared with an input parameter, and any difference between the two is used to drive the output into agreement with the input
Open-loop control system – operates without the feedback loop
Simpler and less expensive
Risk that the actuator will not have the intended effect

96. (a) Feedback Control System and (b) Open-Loop Control System

97. Positioning System Using Feedback Control
A one-axis position control system consisting of a leadscrew driven by a dc servomotor and using an optical encoder as the feedback sensor

98. When to Use an Open-Loop Control System
Actions performed by the control system are simple
Actuating function is very reliable
Any reaction forces opposing the actuation are small enough as to have no effect on the actuation
If these conditions do not apply, then a closed-loop control system should be used

99. Advanced Automation Functions
Safety monitoring
Maintenance and repair diagnostics
Error detection and recovery

100. Safety Monitoring
Use of sensors to track the system's operation and identify conditions that are unsafe or potentially unsafe
Reasons for safety monitoring
To protect workers and equipment
Possible responses to hazards:
Complete stoppage of the system
Sound an alarm
Reduce operating speed of process
Take corrective action to recover from the safety violation

101. Maintenance and Repair Diagnostics
Status monitoring
Monitors and records status of key sensors and parameters during system operation
Failure diagnostics
Invoked when a malfunction occurs
Purpose: analyze recorded values so the cause of the malfunction can be identified
Recommendation of repair procedure
Provides recommended procedure for the repair crew to effect repairs

102. Error Detection and Recovery
Error detection – functions:
Use the system’s available sensors to determine when a deviation or malfunction has occurred
Correctly interpret the sensor signal
Classify the error
Error recovery – possible strategies:
Make adjustments at end of work cycle
Make adjustments during current work cycle
Stop the process to invoke corrective action
Stop the process and call for help

103. Levels of Automation
Device level – actuators, sensors, and other hardware components to form individual control loops for the next level
Machine level – CNC machine tools and similar production equipment, industrial robots, material handling equipment
Cell or system level – manufacturing cell or system
Plant level – factory or production systems level
Enterprise level – corporate information system

104. Levels of Automation